Solidification matrix including a salt of a straight chain saturated mono-, di-, and tri- carboxylic acid

Abstract

A solidification matrix includes a straight chain saturated carboxylic acid salt, sodium carbonate, and water. The straight chain saturated carboxylic acid salt is selected from a salt of a mono-, di-, or tri-carboxylic acid. The solidification matrix may be used, for example, in a solid detergent composition.

The invention claimed is: 
     
       1. A solid detergent composition comprising:
 a hydrate solid solidification matrix consisting essentially of: 
 (a) at least one straight chain saturated carboxylic acid salt selected from the group consisting of: acetic acid, gluconic acid, malic acid, succinic acid, glutaric acid, adipic acid, tartartic acid, citric acid, and sodium citrate; 
 (b) sodium carbonate, and 
 (c) water; 
 less than 0.5% by weight phosphorous; and 
 at least one functional ingredient selected from the group consisting of an alkaline source, a detergent builder, a surfactant or combinations thereof; 
 wherein if heated at a temperature of 120 degrees Fahrenheit, the solid detergent composition is dimensionally stable and has a growth exponent of less than 2%; and 
 wherein the straight chain saturated carboxylic acid salt is combined with the water prior to incorporation into the detergent composition. 
 
     
     
       2. The solidification matrix of  claim 1 , wherein the at least one carboxylic acid salt constitutes between about 1% and about 15% by weight of the composition. 
     
     
       3. The solidification matrix of  claim 1 , wherein the sodium carbonate constitutes between about 20% and about 85% by weight of the composition. 
     
     
       4. The solidification matrix of  claim 1 , wherein the water constitutes between about 2% and about 50% by weight of the composition. 
     
     
       5. A solid detergent composition comprising:
 (a) a hydrate solid solidification matrix consisting essentially of:
 (i) between about 1% and about 15% of at least one straight chain saturated carboxylic acid salt by weight of the solid detergent composition, wherein the straight chain saturated carboxylic acid salt is selected from the group consisting of: acetic acid, gluconic acid, malic acid, succinic acid, glutaric acid, adipic acid, tartartic acid, citric acid, and sodium citrate; 
 (ii) between about 2% and about 50% water by weight of the solid detergent composition; and 
 (iii) between about 20% and about 85% sodium carbonate by weight of the solid detergent composition; 
 
 (b) less than about 40% builder by weight of the solid detergent composition; 
 (c) between about 0.5% and about 10% surfactant by weight of the solid detergent composition; 
 (d) less than about 0.5% phosphorous by weight of the solid detergent composition; and 
 (e) less than about 0.5% NTA by weight of the solid detergent composition; 
 (f) wherein if heated at a temperature of 120 degrees Fahrenheit, the solid detergent composition is dimensionally stable and has a growth exponent of less than 3%; and 
 (g) wherein the straight chain saturated carboxylic acid salt is combined with the water prior to incorporation into the detergent composition. 
 
     
     
       6. The solid detergent composition of  claim 5 , wherein the carboxylic acid salt constitutes between about 1% and about 10% by weight of the solid detergent composition. 
     
     
       7. The solid detergent composition of  claim 5 , wherein the water constitutes between about 5% and about 40% by weight of the solid detergent composition. 
     
     
       8. The solid detergent composition of  claim 5 , wherein the builder constitutes less than about 30% by weight of the solid detergent composition. 
     
     
       9. The solid detergent composition of  claim 5 , wherein the sodium carbonate constitutes between about 45% and about 75% by weight of the solid detergent composition. 
     
     
       10. The solid detergent composition of  claim 5 , wherein the surfactant constitutes between about 1% and about 5% by weight of the solid detergent composition. 
     
     
       11. A solid detergent composition comprising:
 (a) a hydrate solid solidification matrix consisting essentially of at least one salt of a straight chain saturated mono-, di-, or tri-carboxylic acid, sodium carbonate, water, and at least one methacrylate polymer; and 
 (b) at least one functional ingredient;
 wherein the salt of a straight chain saturated mono-, di-, or tri-carboxylic acid is selected from the group consisting of: salts of acetic acid, gluconic acid, malic acid, succinic acid, glutaric acid, adipic acid, tartartic acid, citric acid, and sodium citrate; 
 wherein the salt of the straight chain saturated mono-, di-, or tri-carboxylic acid is combined with the water prior to incorporation into the detergent composition; and 
 wherein the solid composition if heated at a temperature of 120 degrees Fahrenheit is dimensionally stable and has a growth exponent of less than 3%. 
 
 
     
     
       12. The composition of  claim 11 , wherein the functional ingredient is selected from the group consisting of: chelating agents, sequestering agents, inorganic detergents, organic detergents, alkaline sources, surfactants, rinse aids, bleaching agents, sanitizers, activators, detergent builders, fillers, defoaming agents, anti-redeposition agents, optical brighteners, dyes, odorants, enzymes, corrosion inhibitors, dispersants, solubility modifiers and combinations. 
     
     
       13. The composition of  claim 11 , wherein the composition constitutes between about 0.5% and 10% by weight methacrylate. 
     
     
       14. The composition of  claim 11 , wherein the solidification matrix consists essentially of sodium carbonate, water, citric acid salt and polymethacrylate, and wherein the solidification matrix is phosphorous-free. 
     
     
       15. The composition of  claim 14 , wherein if heated at a temperature of 100 degrees Fahrenheit, the solid detergent composition is dimensionally stable and has a growth exponent of less than 3%. 
     
     
       16. The composition of  claim 11 , further comprising at least one polycarboxylic acid polymer. 
     
     
       17. A method of solidifying a detergent composition, the method comprising:
 generating a solid hydrate solidification matrix consisting essentially of: sodium carbonate, water, at least one salt of a straight chain saturated mono-, di-, or tri-carboxylic acid, and at least one methacrylate polymer, wherein the straight chain saturated carboxylic acid salt is combined with the water prior to incorporation into the detergent composition and wherein the straight chain saturated mono-, di-, or tri-carboxylic acid is selected from the group consisting of salts of acetic acid, gluconic acid, malic acid, succinic acid, glutaric acid, adipic acid, tartartic acid, citric acid, and sodium citrate; and 
 forming a solid composition, wherein the solid composition if heated at a temperature of 120 degrees Fahrenheit is dimensionally stable and has a growth exponent of less than 3%. 
 
     
     
       18. The method of  claim 17 , further comprising the step of forming the solid detergent composition into a block, capsule, pellet or tablet. 
     
     
       19. A solid detergent composition comprising:
 (a) a hydrate solid solidification matrix consisting essentially of:
 (i) between about 1% and about 15% by weight of at least one salt of a straight chain saturated mono-, di-, or tri-carboxylic acid; 
 (ii) between about 0.5% and about 10% by weight methacrylate polymer; 
 (iii) between about 2% and about 50% by weight water; and 
 (iv) between about 20% and about 85% by weight sodium carbonate; 
 
 (b) less than about 40% by weight builder; 
 (c) between about 0.5% and about 8% by weight surfactant; and 
 (d) less than about 0.5% by weight phosphorus; 
 (e) wherein the salt of a straight chain saturated mono-, di-, or tri-carboxylic acid is selected from the group consisting of: salts of acetic acid, gluconic acid, malic acid, succinic acid, glutaric acid, adipic acid, tartartic acid, citric acid, and sodium citrate; 
 (f) wherein if heated at a temperature of 100 degrees Fahrenheit, the solid detergent composition is a hydrate solid that is dimensionally stable and has a growth exponent of less than 3%; and 
 (g) wherein the straight chain saturated mono-, di-, or tri-carboxylic acid is combined with the water prior to incorporation into the detergent composition.